Shoulder pad and method of making same



1939- w. H. HAWKINS r AL/ 2,170,199

1 SHOULDER PAD AND METHOD OF MAKING SAME Filed Dec. 9. 1937 um'rsoasrAri-zs PATENT OFFICE wimnm n. Hawkins, Brooklyn, N. 1., and Maurice Seldits. Stamford, Conn, assignors to Freydberg Bree, Ina, Stamford, Conn, a cor poration of New York Application December 9, 1937, Serial No. 178,864: 17 Claims. (01. 2-267) This invention relates to shoulder pads as In preparing the aforementioned shoulder pad,

well as the method of making the same, and more particularly to shoulder pads such as used by tailors and clothing manufacturers in building up the shoulders of coats.

The nature and objects of the invention will become clear from the following description, appended claims, and accompanying drawing forming a part of this specification and in which:

, Figure"! is a top plan view of a shoulder pad blank made in accordance with this invention;

W2 is a section of the shoulder pad blank at stage in the process of making -the same;

Figure-3 is a perspective view of a shoulder pad embodying the principles-of this invention;

Figure 4 is a section of another embodiment of ashoulder pad constituting the instant invention; and

Figure 5 is'a section of another embodiment of a shoulderpadembodying the principles of this invention. x.

the requirements and give the best results in use, pads of the type to which theinstant invention relates should be relatively thick atthe central'zone along one edge and then off gradually and uniformly tothe other oniputer edge which should be relatively. thin. Thus, the shoulder pad .constituting one phase of production of the pads, and more fully explained hereafter, the portions of the facings.

the instant, invention-is relatively thick at the central acne along one edge and gradually and uniformly tapersoff therefrom toits outer or other edge-which-is relatively thin.

the top and bottom thereof. In the preferred form, the filler is formed of a mass of fibers which,

in order; to give the pad its desired form and shape, is soformed that it is relatively thick at the central zone along one edge and then tapers of! gradually and uniformly from said thickened portion towards its other or outeredge to form a relatively thin edge. The facings are coextensive and each of them is of such dimensions that it Projects the-thinedge of {the mass of. with the consequence that I projecting portions thereof are superposed in 'saritactual relationship. Due to, thbmethad employed in the which are in contactuai relationship. are substantially integrally united to each other, as by being felted together. The facings are also united to 3 therewith.

a shoulder pad blank is first prepared, and such blank transversely severed, whereby a pair of complements! shoulder pads is produced. In accordance with one embodiment of this invention, individual cotton or wool fibers are showered under air pressure or suction upon a foraminous support, such as a wire screen, preferably rotating, so that the separate fibers do not extend in any one direction but extend in all directions and become interconnected with each other to form a connected mass wherein the fibers in the central zone of the blank are more numerous and.

its center towards its outer edge which is'rel a tively thin. The precise manner of producing this predetermined shaped mass of fibers is de-' scribed in applications Serial Nos. 86,208 and 170,008,

After the fibers have been formed into the shaped mass as described, the mass may be filled with entrapped air and therefore may be somewhat expanded or puffed. When this condition exists, the blank is compressed in a longititudinal Y direction to force'out the entrapped air. 'lhe resuiting shaped mass of fibers is 015 suificient 1 strength to permit handling and constitutes the filler of the shoulder pad blank and the final pad. The shaped mass of fibers is processed so that it is provided on the top and bottom sur-' faces thereof with facings.

In one embodiment of the invention, a layer of a material containing feltable fibers and in the form of a loose bat, suchas is secured-after garnetting or carding, is disposed on the top and .bottom surfaces of the shaped mass of fibers. The layers of i'eltable fibers are substantially eoexten- 'sive and each is of a size such that the edge thereof projects beyond the thin edge of the shaped mass of the fibers, thereby providing the blank with a marginal portion adjacent its edge and in which the layers containing the feltable fibers are in superposed contactual relationship. When the blank has been assembled as Just described, it is subjected to a felting operation whereby the layers containing the feltablefibers 'are felted in situ on the shaped mass of fibers. Due to this mode of operation, those portions of the layers of feltabie fibersewhich are in superposed contractual relationship are substantially integrally united by being felted together. Also.

due to the fact that the felting operation is carried out in situ on the predetermined shaped mass, the inner surfaces of the layers contained the feltable fibers are substant. lly united to the outer surface of the sipped mass of fibers.

In producing the shoulder pad blank, 1:. pair of oppositely disposed notches are provided in the edge thereof. After the blank has been produced as above described, it is severed along a line connecting the centers of the notches. The resulting two halves constitute a pair of complimental shaped shoulder pads.

The shoulder pad blank may be made of any desired shape and size depending on the requirements of the trade. 1

Though in the preferred embodimentof the invention the fillers are formed by showering cotton or wool fibers under air pressure or suction upon a rotating foraminous support, they may be produced or built up in any desired manner.

If desired, instead of forming the filler of cotton or wool fibers, it may be formed of a'composition containing feltable fibers similar to that which constitutes the facing. Thus, the blank contains fibers having the felting characteristics throughout. When the blank contains feltable fibers throughout, it may be subjected to the felting operation so that it is felted throughout. Alternately, the blank may be subjected to the felting operation for such a period of time so that the surfaces thereof are only felted to constitute felted facings. By varying the time of the felting operation, the blank may be felted to any desired degree, namely, the blank may be felted throughout or have only its facings felted. By varying the degree of felting, pads having different degrees of hardness may be secured.

A pad in which the filler-containing fibers having the felting characteristics and irrespective of the degree of felting thereof will be harder than that in which the filler is formed of cotton or wool. If a pad is desired of a hardness which is intermediate that obtained when cotton or wool fibers and feltable'fibers are'used, a mixture of cotton fibers and feltable fibers may be used. A satisfactory fiber mixture is one containing approximately 90% cotton fibers and 10% feltable It is within the scope of this'invention to make the filler of a mixture of different fibers felted throughout or not as desired.

As the feltable fiber which constitutes the facing or the filler when so desired, any fibers which possess the felting characteristic may be used. In the preferred form of the invention, hatters waste constitutes the feltable fibers. If desired, the hatters wastemay have in it carbonized or depitched noils or Texas wool or any other wools that have felting characteristics. Still further, if desired, a little China cotton or other adulterant may be incorporated in the mass.

The fibers having felting eharacteristics are garnetted or carded and formed into loose bats..

From these loose bats discs of the desired dimensions are cut or stamped and these discs are applied to the shaped fillers and result in the facings of the pads.

The felting operation is effected by appropriately rubbing the facing in the presence of water and/or steam. In one embodiment of the invention, the felting operation is accomplished in an apparatus which comprises a pair of members having relative movement therebetween, as for example, a stationary plate and an oscillating mend-like, pear-shaped or of shape and disposing it between the .layers of' material containing fibers having felting characteristics, another embodiment of the invention comprises producing the shoulder pad blank in readiness for the felting operation in the apparatus employed for the making of .the filler. In this embodiment, the fibers having the felting characteristics are showered under air pressure or suction onto the rotating foraminous support until the desired thickness thereof has been built up. Then the fibers which are to form the filler are showered onto the already formed layer of feltable fibers. When the filler has reached the desired dimensions, further showering thereof is discontinued and the, fibers having felting characteristics showered onto said filler. When the desired thickness of the feltable fibers has been secured, the blank is removed from the showering apparatus, which, incidentally, is of the type disclosed in applications Serial Nos. 66,208 and 170,- 008, and, after removing the entrapped air, is subjected to'the felting operation.

The procedure described in the preceding paragraph may be employed if the filler is also formed of fibers having the felting characteristics.

Now referring to the drawing wherein several illustrative embodiments of the invention are shown and wherein like reference numerals designate like parts, the reference numeral I designates a shoulder pad blank produced in accordance with this invention and provided with oppositely disposed V-shaped notches 2 in the edge thereof. The shoulder pad blank i is so constructed that when it is cut transversely thereof along the line 3 there will be obtained two complemental shoulder pads, one of which is illustrated in Figure 3 and designated by the reference numeral 4.

In one form of the invention, to produce the shoulder pad blank i, the filler 5 formed of the selected fiber, for example, cotton, is formed or shaped into the predetermined contour, as above described. Discs 6 and 1 of a loose" bat containing fibers having the felting characteristic are disposed on the top and bottom of the shaped filler. It is to be noted that each of the discs 6 and 1 extends beyond the thin edge 8 of the filler 5. In other words, the marginal portion 9 of the disc 6 is superposed on and in contactual relationship with the marginal portion ID of the disc 1. The assembly at this stage of the process,

shown in Figure 2 of the drawing, is now subjected to a felting operation as hereinbefore described with the result that the fiber constituting the discs 6 and I is felted. The marginal portions 9 and Ill of the discs 6 and 1 are substantially integrally united by being felted together and provide the blank I with the marginal portion I I which consists substantially of felted material. Due to the fact that the facings are felted in situ on the filler, the surfaces of the final facings contacting with the surfaces of the shaped filler 5 are more or less felted together at the zone of contact thereof.

Though for purposes of illustration the pad blank I has been shown as substantially heartshaped, it is obvious that it may be circular, diaany shape to suit the requirements of the various clothing manufacturers.

' blank I and hence the pad. 4 may be such as is desired by the trade.

As is clearly shown in Figure 2, the filler 5 is relatively thick at its central zone and gradually tapers off therefrom in all directions to the relatively thin peripheral edge 8 and this shape of the filler 5 is substantially retained in the final product. The facings of the final product do not materially change the general contour of the fillers.

It is to be noted that the facings formed from the discs 6 and I completely envelope the filler 5 and follow generally the contour thereof. By virtue of the fact that the marginal portions 9 and Ill are felted together, the top and bottom facings may be said to be substantially continuous,

In some cases it may be desirable to provide the pad with a stiffener. When this is desired, a

piece of any suitable stiffening material, suchas,

for example, buckram l2, (see Figure 4) is incorporated in the filler 5 during the production thereof.

As previously explained, the filler 5, instead of being made of cotton-or wool, may be formed of a material containing fibers having the felting characteristic. Such anembodiment of the invention is illustrated in Figure 5 of the drawing. In this embodiment of the'invention, it is to be noted that the facings 5 and I have been felted and that the marginal portion ll consists of a substantially unitary structure. If desired, the felting operation may be containedso that the I product is felted throughout.

The shoulder pad 4, resulting when the shoulder pad blank I is cut along the line 3, has a relatively thick zone l3 along the cut edge and gradually tapers oif therefrom to thin mar-- ginal portion l4 thereof which is the same as the marginal portion ll of the blank I. The facings l5 and I6, except for beingsevered at the cut edge of ,the pad 4, are substantially the same as the facings formed from'the discs 5 and 1. Due to the marginal portion l4, the facings l5 and 16 may be said to be formed of substantially one piece of .felt.

The pad 4 shown in Figure3 has a substantially fiat bottom and a convex (arched) top. The invention is notrestricted to such a shape and contour. The pad 4 may be formed so that it has substantially the form and shape that it has when sewed into a coat. This can be secured by forming the pad blank I so that after severance the desired shaped pad may be secured or by appropriately forming the pad 4 after the production thereof.

Irrespective .of the form and shape of the pad 4, the top and bottom surfaces thereof are formed of felt and the pad possesses the desired fiexibility and resiliency as to lend itself for easy incorporation in a coat. It can be stitched very readily and quires no special precautions when being sewed into place, in a coat. It is free from stitches and -no means other than those herein described are necessary to maintain the component parts thereof together.

Since it is obviousthat'various changes and modifications may be made in the above description without departing from the nature or spirit thereof, this invention is not restricted thereto except as set forth in the appended claims.

We claim:

1. A shoulder pad blank comprising a filler Similarly, the dimensions of the pad having a thick central portion and tapering off therefrom to a relatively thin peripheral edge, and a facing formed of a felted material on both the top and bottom of said filler, each of said facings extending beyond and forming a mar-- ginal zone adjacent said thin edge, said facings being felted together in said marginal zone.

2. A shoulder pad comprising a filler relatively thick at a zone along one edge and tapering off gradually from the thick portion to a relatively thin edge, and a facing on both the top and bottom of said filler, said facings being formed of felted material and felted together adjacent the said thin edge.

3. A shoulder pad comprising a mass 'of fibers relatively thick at a zone along one edge and tapering off gradually from the. thick portion to form a relatively thin edge, a felted material on the top of said mass and extending beyond said thin edge thereof, and a felted material on the bottom of said mass and extending beyond said thin edge thereof, said felted materials being substantially coextensive and felted together at the portions thereof extending beyond said thin edge.

4. A shoulder pad free of stitches comprising a mass of fibers relatively thick at a zone adjacent along one edge thereof and tapering off gradually from said thick portion to form a relatively thin I edge, a facing on the top of said mass and extending beyond the thin'edge thereof, a facing acteristics, said layers having their marginal zones in superposed contactual relationship, and felting said'layers in situ to provide felted facings and whereby said marginal zones in superposed ccntactual relationship are felted together.

6. In a method for making shoulder pads, the

, steps which comprise disposing a filler between two layers containing fibers having felting char-- acteristics, said layers having their marginal zones in-superposed contactual relationship, felting said layers in situ to provide felted facings and-whereby said marginal zones in superposed contactual relationship are felted together, and severing the resulting product transversely-thereof to form a pair of complemental shoulder pads.

7. A shoulder pad blank comprising a filler and a. substantially integral and continuous felted ,material enveloping said filler and constituting a facing therefor on both thetop and bottom surfaces thereof, said filler being formed of a showered mass of fibers wherein the fibers extend in all directions and are interconnected with each other and wherein the fibers in the central zone are more densely compacted than those at the outer edgethereof and the density gradually decreases outwardly.

8. A'shoulder pad blank having a facing formed of a felted material on both the top and bottom of said blank, said facings being felted together along the marginal zone adjacent the edge of said blank and a filler interposed between said facings, said fillerbeing formed of a showered mass of fibers wherein the fibers extend in all directions and are interconnected with each other and wherein the fibers in the central zone are more densely compacted than those at the outer edge thereof and the density gradually decreases outwardly.

9. A shoulder pad blank comprising a filler having a relatively thin peripheral edge, and a facing formed of a felted material on both the top and bottom of said filler, each of said facings extending beyond and forming a marginal zone adjacent said thin edge, said facings being felted together in said marginal zone, said filler being formed of a showered mass of fibers wherein the fibers extend in all directions and are interconnected with each other and wherein the fibers in the central zone are more densely compacted than those at the outer edge thereof and the density gradually decreases outwardly.

10. A shoulder pad comprising a filler relatively thick at a zone along one edge and tapering off gradually from the thick portion to a relatively thin edge, and a facing on both the top and bottom of said filler, said facings being formedof felted material and felted together adjacent the said thin edge, said filler being formed of a showered mass of fibers wherein the fibers extend in all directions and are interconnected with each other and wherein the fibers in the central zone are more densely compacted than those at the outer edge thereof and the density gradually decreases outwardly.

11. A shoulder pad comprising, a mass of fibers relatively thick at a zone along one edge and tapering oif gradually from the thick portion to form a relatively thin edge, a felted material on the top of said mass and extending beyond said thin edge thereof, and a felted material on the bottom of said mass and extending beyond said thin edge thereof, said felted materials being substantially coextensive and felted together at the portions thereof extending beyond said thin edge, said filler being formed of a showered mass of fibers wherein the fibers extend in all directions and are interconnected with each other and wherein the fibers in the central zone are more densely compacted than those at the outer edge thereof and the density gradually decreases Jut- 12. A shoulder pad free of stitches comprising a mass of fibers relatively thick at a. zone adjacent along one edge thereof, and tapering off gradually from said thick portion to form a relatively thin edge, a facing on the top of said mass and extending beyond the thin edge thereof, a facing on the bottom of said mass and'extending beyond the thin edge thereof, the extending portions of the said top and bottom facings being in superposed contactual relationship, said fac-- pressure upon a rotating foraminous support to producea mass of fibers wherein the fibers extend in all directions and are interconnected and wherein the fibers in the central zone are more densely compacted thanthose at the outer edge of the mass and the density gradually decreases the steps which comprise showering fibers under air pressure upon a rotating foraminous support to produce a mass of fibers wherein the fibers extend in all directions and are interconnected and wherein the fibers in the central zone are more densely compacted than those at the outer edge of the mass and'the density gradually decreases outwardly, disposing said massto constitute a filler between two layers containing fibers having felting characteristics, said layers having their marginal zones in superposed contactual relationship, and felting said layers in situ to provide felted facings and whereby said marginal zones in superposed contactual relationship are felted together.

15. In a method for making shoulder pads, the steps which comprise showering fibers under air pressure upon a rotating foraminous support to produce ,a mass of fibers wherein the fibers extend in all directions and are interconnected and wherein the fibers in the central zone are more densely compacted than those at the outer edge of the mass and the density gradually decreases "outwardly, disposing said mass to constitute a filler between two layers containing fibers having felting characteristics, felting said layers in situ on said filler to provide felted facings, and severing the resulting product transversely thereof to form a pair of complemental shoulder pads.

16. In a method for making shoulder pads, the steps which comprise showering fibers imder air pressure-upon a rotating foraminous support to produce a mass of fibers wherein the fibers extend in all directions and are interconnected and wherein the fibers in the central zone are more densely compacted than those at the outer edge of the mass and the density gradually decreases outwardly, disposing said mass to constitute a filler between two layers containing fibers having felting characteristics, said layers having their marginalz'ones in superposed contactual relationship, "felting said layers in situ to provide felted facings and whereby said marginal zones in superposed contactual relationship are felted together, and severing the resulting product transversely thereof to forms. pair of complemental shoulder pads.

1'7. A method of making shoulder pad blanks which comprises showering feltable fibers suspended in air on to a' rotating foraminous support until the desired thickness has been built up, showering fibers to constitute the filler and suspended in air on to said built up rotating mass of feltable fibers until the desired thickness has been built up, showering feltable fibers suspended in air on the resulting built up rotating mass until thedesired thickness has been secured, and subjecting the thus produced mass to a felting operation whereby the feltable fibers are felted together;

-WILLIAM H. HAWKINS. MAURICE SEIDITZ. 

